Exp Pr Eq040 en r0_1 Piping

EQUIPMENT PIPING

TRAINING MANUAL Course EXP-PR-EQ040 Revision 0.1

Exploration & Production Equipment Piping

EQUIPMENT PIPING SUMMARY 1. OBJECTIVES ..................................................................................................................4 2. THE FUNCTIONS OF PIPING.........................................................................................5 2.1. INTRODUCTION.......................................................................................................5 2.2. PIPING NETWORK...................................................................................................5 2.3. PIPES........................................................................................................................6 2.4. FLANGES .................................................................................................................6 2.5. GASKETS .................................................................................................................7 2.6. BLINDS .....................................................................................................................7 2.7. EXERCISES..............................................................................................................8 3. PIPING COMPONENTS ..................................................................................................9 3.1. TUBES OR PIPES ....................................................................................................9 3.1.1. Characteristics ....................................................................................................9 3.1.2. The various types .............................................................................................10 3.1.3. The various classes ..........................................................................................10 3.2. FLANGES ...............................................................................................................12 3.2.1. Various flanges .................................................................................................12 3.2.1.1. Various types of flanges .............................................................................12 3.2.1.2. The various types of faces .........................................................................13 3.2.1.3. The various classes ...................................................................................15 3.2.2. Characteristics ..................................................................................................17 3.2.2.1. American standards ...................................................................................17 3.2.2.2. The French standards AFNOR...................................................................21 3.2.3. The various types of assembling ......................................................................22 3.2.4. Tightening the flanges ......................................................................................24 3.2.4.1. Tightening torque .......................................................................................24 3.2.4.2. Tools for tightening by hydraulic tensioning ...............................................26 3.2.4.3. Installing a new gasket ...............................................................................27 3.2.5. The main fittings used.......................................................................................29 3.3. GASKETS ...............................................................................................................30 3.3.1. The various types .............................................................................................30 3.3.1.1. Soft gaskets ...............................................................................................30 3.3.1.2. Metallic gaskets..........................................................................................32 3.3.1.3. The metal-elastomer gaskets .....................................................................33 3.3.2. Using gaskets ...................................................................................................34 3.4. BLINDS ...................................................................................................................36 3.4.1. The various types .............................................................................................36 3.4.1.1. Flush joints .................................................................................................36 3.4.1.2. The reversible blinds ..................................................................................36 3.4.1.3. Blind flanges...............................................................................................37 3.4.2. Gasket brackets................................................................................................38 Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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3.5. ADVANTAGES AND DRAWBACKS OF THE VARIOUS TYPES ...........................40 3.5.1. Carbon steel .....................................................................................................40 3.5.2. Stainless steel...................................................................................................40 3.5.3. Synthetic materials ...........................................................................................41 3.6. EXERCISES............................................................................................................41 4. REPRESENTATION AND DATA ...................................................................................42 4.1. TUBES OR PIPES ..................................................................................................42 4.1.1. Pipe classification .............................................................................................42 4.1.2. Pipe Identification principle according to the TOTAL specs..............................42 4.2. REPRESENTATION ON P&ID................................................................................45 4.3. DIMENSIONING......................................................................................................48 4.3.1. The dimensioning criteria..................................................................................48 4.3.2. Dimensions of the pipes ...................................................................................48 4.3.3. Choice and principle of changing the class.......................................................51 4.4. EXERCISES............................................................................................................51 5. PIPING OPERATIONS ..................................................................................................52 5.1. PRECAUTIONS BEFORE START-UP....................................................................54 5.2. PRECAUTIONS TO TAKE BEFORE SHUTDOWN OR INTERVENTIONS ............54 5.3. 1st DEGREE MAINTENANCE .................................................................................55 5.4. EXERCISES............................................................................................................55 6. TROUBLESHOOTING...................................................................................................56 6.1. PIPING PROBLEMS ...............................................................................................56 6.1.1. External corrosion.............................................................................................56 6.1.2. Internal corrosion ..............................................................................................58 6.1.3. Other causes of deterioration............................................................................58 6.1.4. Protections........................................................................................................59 6.2. NOTES....................................................................................................................59 7. GLOSSARY ...................................................................................................................60 8. SUMMARY OF FIGURES..............................................................................................61 9. SUMMARY OF TABLES................................................................................................62

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1. OBJECTIVES

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2. THE FUNCTIONS OF PIPING 2.1. INTRODUCTION The piping or pipe is a network unit which transports a fluid from one type of equipment to another. The various transported fluids: Incompressible fluids (liquid) Compressible fluids (gas) Fluids under high pressure Mixed fluids: liquid gas / slurries / solids

Flow principles Difference in pressure between an upstream and a downstream equipment Pump (liquid) Compressor (gas) Gravity flow

2.2. PIPING NETWORK The piping network is a complete network (pipes, valves and other accessories which are connected to correctly perform a specific job.) A familiar example of a piping system is the network of water pipes in houses. This system includes all the components which are needed to bring the water to the house and distribute it to the various places within it. The piping systems are essential for the successful operation of any industrial plant. There are various systems, each with its own function. For example the gas oil storage tanks for boiler burners.

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Figure 1: Piping network

2.3. PIPES Pipes are used mostly to permit fluid flow and must support specifically determined pressure, compression and tensile stress. They must also resist buckling.

2.4. FLANGES The flanges are used to ensure a detachable and leak-proof connection between two piping units (piping section, connection on a rotating machine, on a vessel).

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2.5. GASKETS Placed between 2 flanges, a sealing joint must have the following qualities: Be sufficiently plastic to absorb surface irregularities Withstand operating pressures without breaking Have enough springback to permit the flow of the fluid to the outside (leak) Not be attacked by the transported fluid

2.6. BLINDS Blind flanges are installed to isolate a piping section or a storage capacity, each time one needs to ensure that no leakage will occur. When shutting down a unit, the plates provide 3 essential functions: Sectional (or isolating) blinds The blinds are placed at the battery limits of a unit upon shut-down, in order to completely isolate the unit from the rest of the installations which are still operating. Working blinds They are placed as close as possible to the vessels, the apparatus and the machines, which have to be inspected, overhauled or otherwise worked on. Test blinds Their purpose is to isolate and resist the test pressures in the apparatus, during the regulation tests ordered by the mining or inspection department.

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2.7. EXERCISES 1. What is a piping network?

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3. PIPING COMPONENTS 3.1. TUBES OR PIPES 3.1.1. Characteristics A tube is defined by its diameter, the thickness of the envelope and the grade of the steel of which it is composed. The nominal pipe size expressed according to French or American standards is but a simple number used to classify the tubes.

Figure 2: The definitions of a tube

Correspondence in diameters between French standards (AFNOR) and American (ANSI): French nominal pipe size Diameter in inches True outer diameter

NPS 50 2" 60,3

NPS 100 4" 114,3

In the French standard AFNOR the thickness is expressed in mm. In the American standard ANSI the thickness is defined by the Schedule Number, (according to the metal) given in the form of a table.

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This standard is defined by the American code ANSI B 36-10 for carbon steel according to the internal pressure (P) and to the allowable stress of the metal at the operating temperature.

3.1.2. The various types Three types are distinguished: Welded tubes Obtained through heat or cold they have a welded joint coefficient. In accordance with the manufacturing process of the envelope, the weld can be longitudinal (butt seam tube) or helicoidal (spiral seam tube). Centrifuge tubes Obtained by means of a metal flow in a rotating cylindrical mould, these tubes are reserved for special steels. Seamless tubes They are mostly used in the oil and petrochemical industry. They are obtained by heating a steel billet up to about 1250°C, then after a piercing made by a metal pear, the obtained tube is laminated and calibrated.

3.1.3. The various classes API: Mainly used for very high-pressure oil applications. ASME: Standard, frequently used flanges and tubes. The wellheads are API equipped. The manifolds are either API or ASME equipped. The utilities are usually ASME equipped.

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Figure 3: Used abbreviations Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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3.2. FLANGES 3.2.1. Various flanges 3.2.1.1. Various types of flanges Welding neck Used when NPS >= 2” in most cases (the most resistant)

Figure 4: Welding neck flange Socket welding Only used for classes 150 and 300 (carbon steel)

Figure 5: Socket welding flange Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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Threaded Used for the utility lines, do not use for the process lines

Figure 6: Threaded flange

3.2.1.2. The various types of faces Flat face (Flat Face FF) Used for flanges in reinforced iron and plastic (SVR)

Figure 7: Flat face

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Raised Face (RF) Used for classes 150 to 600

Figure 8: Raised face

Ring joint (Grooved for Ring Joint RJ) Used for classes 900 to 10 000

Figure 9: Ring joint

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3.2.1.3. The various classes

Class TOTAL

B01

D01

F01

ASME class

150 RF

300 RF

600 RF

Material (corrosion in mm)

C.S. (1.27)

Fluid

Hydrocarbons (corrosionresistant gas or liquid) Pressurized drains Corrosion-resistant flare gas, Fuel gas Gas oil Diesel Nitrogen Oily water Cooling water (corrosionresistant) Tail water (corrosionresistant) Methanol Glycol

Temperature

-29 °C to 220 °C

C.S. (1.27)

Hydrocarbons (corrosionresistant gas or liquid) Pressurized drains Fuel oil (medium pressure), Nitrogen (medium pressure), Methanol Glycol

-29 °C to 200 °C

C.S. (1.27)

Hydrocarbons (corrosionresistant gas or liquid) Low pressure hydraulic units Methanol Glycol

-29 °C to 200 °C

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Class TOTAL

G01

H01

J01

ASME class

900 RJ

1500 RJ or Hub connectors

2500 RJ or Hub connectors

Material (corrosion in mm)

Fluid

Temperature

C.S. (1.27)

Hydrocarbons (corrosionresistant gas or liquid) Deacidified gas (HP sweet gas) Methanol Glycol

-29 °C to 200 °C

C.S. (1.27)

Hydrocarbons (corrosionresistant gas or liquid) deacidified gas (HP sweet gas) Injection water (corrosionresistant, degassed sea water) MP hydraulic power unit Methanol Glycol

-29 °C to 200 °C

C.S. (1.27)

Hydrocarbons (corrosionresistant gas or liquid) deacidified gas (HP sweet gas) Injection water (corrosionresistant, degassed sea water) HP hydraulic power unit Methanol Glycol

-29 °C to 200 °C

Table 1: The various classes of flanges (TOTAL and ASME)

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3.2.2. Characteristics A flange is defined by various elements: Its type : is in accordance with the use, the stress and both operating pressure and temperature, Its diameter : is in accordance with the piping line diameter, Its face : is in accordance with the sealing joint which will be used, Its series or its class : it characterizes the capacities to support both pressure and temperature, Its material: is in accordance with pressure, temperature and with the resistance to the corrosion of the transported fluid.

3.2.2.1. American standards Since the pipes are classified by “Schedule” the flanges are classified according to the following standards, in nominal pressures (NP), class or series. API (American Petroleum Institute) ASME (American Society of Mechanical Engineers) ASME used to be called: American Standard Association (ASA ⇒ 1966). United States of America Standard (USAS ⇒ 1969) American National Standard Institute (ANSI ⇒ 1982).

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New name

Old name

NP 20

Class 150 #

NP 50

Class 300 #

NP 100

Class 600 #

NP 150

Class 900 #

NP 250

Class 1 500 #

NP 420

Class 2 500 #

Table 2: The new names for the ANSI flanges

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Class

Temperature

Psi

- 29 °C to 38 °C

260 °C

454 °C

150

19 bars

10.35 bars /150 psi

300

49.6 bars

20.70 bars / 300 psi

400

66.2 bars

27.60 bars / 400 psi

600

99.3 bars

41.40 bars / 600 psi

900

148.9 bars

62.10 bars / 900 psi

1 500

248.4 bars

103.45 bars / 1 500 psi

2 500

414 bars

172.40 bars (2 500 psi)

Table 3: Maximum pressure allowed according to ASME standard B 16, 5

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Value in lbs

Use

150

Low pressure

300

Intermediate pressure

600

High pressure

900

Very high pressure

1500

Extremely high pressure

2500

Maximum pressure

Table 4: The use of the various classes

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Figure 10: Pressure curve according to the series 3.2.2.2. The French standards AFNOR In the beginning, taking in account the material of the flanges, the series were expressed in NP (nominal pressure given in bar) in correspondence with the maximum pressure that the assembly could support, up to a limited temperature of 110 °C. The values of the standardized NP series were the following: NP : 2.5 – 6 – 10 – 16 – 25 – 40 – 64 – 100 – 160 – 250 – 320 – 400 – 640 – 1000 Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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3.2.3. The various types of assembling

Figure 11: Ring type joint facing

Figure 12: Flat face Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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Figure 13: Raised face

Figure 14: Male and female facing

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Figure 15: Tongue and groove facing

3.2.4. Tightening the flanges The flanges must be tightened in a very specific order, for good alignment between the two flanges and for equal squeezing of the gasket, resulting in a tight seal. 3.2.4.1. Tightening torque A torque wrench is an adjustable tool, which limits the tightening torque of the screw and nut so that they may be installed optimally. The oldest models are fully mechanical and emit a click when the torque (adjustable by means of a cursor on the wrench) has been reached. The wrench must absolutely be reset before tightening each time. Current models no longer need to have the wrench reset. They now have an electronic part, with a display and a keypad, connected to a strain gauge which triggers a buzzer to warn the operator when the tightening is sufficient. No need to reset the wrench, you only need to change the batteries once they are flat. Example: Usually a tightening torque is expressed in daN.m (1 decaNewton.m = 10 Newton.m). The nuts of a cylinder head will, for example, be tightened at 9 daN.m.

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Table 5: Example of a table with tightening torques Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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3.2.4.2. Tools for tightening by hydraulic tensioning The hydraulic bolt tensioning cylinders are described as tools for tightening by means of hydraulic pull as they tighten the screw without any interference fit stress (friction or torsion). The operating principle of the hydraulic bolt tensioning cylinder (tensioning method) is briefly explained, along with its advantages, and compared to tightening with a conventional torque. The use of the tensioning method allows for large tightening reproducibility from one screw to the other (tolerance close to ±2, 5%).

The hydraulic bolt tensioning cylinder is placed on the external thread (passing above the nut).

Figure 16: Positioning the hydraulic bolt tensioning cylinder on the screw

The hydraulic pressure is provided by a hydraulic power pack pulls on the screw without exerting any torsional or frictional stress. There is a linear relationship between the hydraulic pressure transmitted to the hydraulic bolt tensioning cylinder and the tension force of the screw, thereby ensuring a high degree of precision. Figure 17: Drawing of the screw

Once the required pressure has been reached, the nut is put in contact with the bearing surface, without any frictional stress, using a hand torque wrench. Thanks to this principle, and in the absence of all interference fit stress (torsion and friction), it is possible to tighten screws up to 98% of the elastic limit. Place the hydraulic bolt tensioning cylinder on the screw, using a spanner wrench or an electric screwdriver. When the selected hydraulic pressure has been reached, the screw is pulled without any frictional or torsional stress.

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Place the nut on the contact surface using a spanner wrench. The screw is tight.

Figure 18: Positioning the nut

Advantages: Great tightening force achieved with small sized tools (Thread W 510 or M340; 45,000 kN) No torsional stress in the screw Only tensile stress in the screw Tightening of several screws simultaneously (multi-tensioning system) A hydraulic bolt tensioning cylinder can be used for several screw sizes Perfect use for stainless steel as there is no risk of cold junction (seizing) of the thread. The sealing surfaces, subject to high temperatures (example: in gas turbines), can be disassembled even after long periods of time. The linear relationship between the tension force of the hydraulic bolt tensioning cylinder and the hydraulic pressure, ensures significant reproducibility

3.2.4.3. Installing a new gasket Visually examine and clean the flanges, the bolts, the nuts and the washers Lubricate the bolts and the nuts Make sure that the gasket is in accordance with the characteristics (type, material, ND, the class…) Install the gasket and the bolts; use your hands to tighten the nuts and examine the space to ensure the uniformity Pre-tighten the nuts to a torque of 10/20 ft.lbs, do not exceed 20 % of the end torque Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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Proceed to the final tightening using the model below, while tightening in the indicated order and checking each of the bolts Retighten after 24 h or with every rise in temperature of the pipe

Figure 19: Tightening sequence of the bolts

Figure 20: Tightening sequence for various types Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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3.2.5. The main fittings used

Name

Description and use

Fitting

A male and female fitting which connects two straight pipes

Union

A female fitting which can be unscrewed

Elbow (angle of 45º or 90º)

Used to change the direction of a pipe

Sleeve

With a different internal and external thread. It joins one pipe to another, smaller pipe

Tee (T)

Joins 3 pipes together in a T

Y gasket

Joins 3 pipes together in a Y

Cross / + gasket

Joins 4 pipes together in a +

Plug

Solid male thread to temporarily (un)plug a pipe

Cap

Solid plug with internal thread to temporarily (un)plug a pipe

Nipple

A male fitting of a small section often used to fit other fittings

Reducing sleeve

Serves to reduce the diameters of a pipe

Table 6: The main fittings Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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3.3. GASKETS 3.3.1. The various types Gaskets can be classified into three large families which comprise: The soft gasket The metallic gaskets The metal-asbestos gaskets Remark: Gaskets containing asbestos are prohibited Flat gaskets in PTFE (Polytetrafluoroethylene) or containing PTFE are not accepted Graphite-impregnated flat gaskets must not be used with anticorrosion alloys when they used in contact with salt water 3.3.1.1. Soft gaskets The most commonly used are soft fibrous gaskets composed of a mixture of elastomers. The elastomer provides the mechanical resistance To improve the mechanical resistance, a very fine metal screen can be imbedded in the middle during manufacturing. Numerous elastomers can make up the composition of these gaskets: Viton, rubber … Some gaskets are coated with PTFE.

Figure 21: Soft gasket

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Synthetic rubber gaskets Thickness:

3 mm for NPS 8”

Figure 22: Synthetic rubber gasket

Synthetic fibre gaskets (klinger type) Must be impregnated with a non-stick coating on both faces

Figure 23: Synthetic fibre gasket

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3.3.1.2. Metallic gaskets They are used for operating conditions with very severe pressures and temperatures. There are three main types: The ring type joints RTJ with oblong or trapezoidal section The flat gaskets : smooth, ribbed or corrugated The slim corrugated gasket with or without packing The lens-shaped gaskets Their low elasticity demands evenly-distributed tightening (tightening sequence of the heads, extent of their pull during tightening, flatness and alignment of the flanges). Otherwise, occurrence of a leak is highly probable.

Spiral wound gaskets The spiral part must be made of stainless steel The fitting can be made of a material based on PTFE or graphite, with a corrosion inhibitor The two rings are made of epoxy-coated carbon steel or in stainless steel

Figure 24: Spiral wound gasket

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Ring joint gaskets The section can be oval or octagonal shaped The gaskets must have a hardness (HB) < to that of the flanges in order to guarantee a tight sealing

Figure 25: Ring joint gaskets

3.3.1.3. The metal-elastomer gaskets A metal covering (copper, aluminium, stainless steel …) coats an elastomer compound forming the gasket core.

Figure 26: Metal-elastomer gasket

When placed in a groove, these gaskets must have the crimped side facing the bottom of the groove. Figure 27: Positioning a metal-elastomer gasket

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3.3.2. Using gaskets The gaskets must be fully adapted to the operating conditions (diameter, series and quality). The gaskets are not reusable with exception of some metallic gaskets which can be reused provided they are not deformed or scratched. The flange faces must not have deteriorations such as: scratches, corrosion, substantial pitting … The gaskets must be perfectly centred between the flanges. The tightening technique must ensure regular gradual squeezing over the whole surface of the gasket. The metal coverings are sensitive to various types of corrosion. It is good to verify the state of the gaskets after use. A strip, of PTFE, expanded graphite and ceramic fibres is wound in a spiral together with a metal strip in the form of a V. This type of gasket is called a spiral wound gasket.

When used with raised face flanges, they are fitted with an outer alignment ring.

To prevent the metal spiral from deteriorating on the fluid side, they can be equipped with an internal ring

Figure 28: Gasket with inner reinforcement and alignment ring

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FLUID

MATERIAL

Water

Rubber

Cold oil

Neoprene

Hot oil

Ingot iron

Low temperature gas

Rubber

High temperature gas

Acids

Elastomer Metal resistant to corrosion

Table 7 : Type of material according to the fluid

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3.4. BLINDS 3.4.1. The various types 3.4.1.1. Flush joints They are simple metal discs with a tail and are inserted in case of need.

Figure 29 : Flush joint

3.4.1.2. The reversible blinds The spectacle blinds are permanently installed. In open position they let the fluid pass; in closed position they stop the circulation.

Figure 30: Spectacle blind

They are placed between two flanges.

Figure 31: Assembling a spectacle blind

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Figure 32: Spectacle blind in open position

Figure 33: Spectacle blind in closed position

3.4.1.3. Blind flanges

Figure 34: Blind flanges Training Manual: EXP-PR-EQ040-EN Last revision: 16/04/2007

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Blind flanges are installed to close the ends of the pipes, the valves or the equipment. The bolts pass through the blind flanges and the equipment flanges. After the placing of a gasket the bolts must be tightened according to specifications.

Figure 35: Blind flange

ATTENTION: Flanges, gaskets and bolting must correspond to the class of the initial flange.

3.4.2. Gasket brackets The pipes are submitted to stress from: Their own weight Vibrations Dilatation It is therefore imperative that they be supported to maintain the network in good operating condition.

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The various types of brackets: Fixed clamp type, or well welded Gliding bracket, permitting a liberty to move in an axis, or a design to permit the dilatation of the pipe. Special bracket of a spring box type

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3.5. ADVANTAGES AND DRAWBACKS OF THE VARIOUS TYPES 3.5.1. Carbon steel Advantages Price of the raw material Easy to weld Good resistance to pressure Drawbacks Sensitive to corrosion

3.5.2. Stainless steel There are various qualities of stainless steel; example: 304/ 316 / 316 L The 304 being at the bottom-of-the-line; used in places which demand a simple corrosionprotection. The more sophisticated 316L is used in more corrosive sectors. The numbers correspond with the various percentages of Nickel which are employed during manufacturing Advantages Resists corrosion Drawbacks Difficult to weld Galvanic cell formation with the carbon steel from the structures Price

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3.5.3. Synthetic materials

Advantages Corrosion resistant Lightness Easy to apply Does not need hot working ( except for some thermoplastic components) Drawbacks Hardly withstands pressure Fragile to shock Poor fire resistance

3.6. EXERCISES

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4. REPRESENTATION AND DATA This chapter describes …

4.1. TUBES OR PIPES 4.1.1. Pipe classification Networks are classified as process or service lines. Service pipes transport water, steam, gas and air which is needed for the process utility systems. Most of the pipes are colour-coded. The transported fluid is identified by the colour and the code. For example, the pipe which transports the water for the fire-fighting facilities is usually painted red and is also identified with white lettering.

4.1.2. Pipe Identification principle according to the TOTAL specs The class is identified by a code, composed of: 1 letter and 3 numbers Example: B 511 B ⇒ Class = 150 lbs (pounds or 1lbs is equal to 453 gr) ASME class 51 ⇒ Liquid or hardly corrosive gas hydrocarbons 1 ⇒ Corrosion thickness = 1.5 mm

Classes: A

B

C

D

E

F

G

H

J

125

150

300

600

900

1500

2500

TUBING

10 000

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Corrosion thicknesses: 0 ⇒ 0.0 mm 1 ⇒ 1.5 mm 2 ⇒ 3.0 mm 3 ⇒ 6.0 mm

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4.2. REPRESENTATION ON P&ID To be able to read the various documents at our disposal on the oil sites, especially concerning the piping, it is necessary to KNOW how to recognise and interpret the symbols, lines and other information found on the PFD and P&ID. A PID (Piping & Instrumentation Diagram) usually offers a minimum amount of information on the pipe (this is especially important when making modifications to the lines) The pipe lines with their symbols The valves with their system for opening and closing. The plugs

Be sure to check that you are working on the latest version.

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Figure 36: PID Fuel gas scrubber Training Manual EXP-PR-EQ040-EN Last revision: 16/04/2007

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4.3. DIMENSIONING 4.3.1. The dimensioning criteria The dimensioning of a pipe and of the associated elements is determined by what it will be used for (flow rate, velocity, pressure, location) There are formulas which provide the correct dimensions. Efforts are made not to oversize the tubes because of problems with weight, price and excessive thickness.

4.3.2. Dimensions of the pipes Pipe dimensions are standardised in inches and also in the metric system. The most commonly used are the measurements in inches:

½” - ¾” - 1” - 1½” - 2” - 3” - 4” - 6” - 8” 10” - 12” - 14” - 16” - 18” 20” - 24” 30” - 36” 42” - 48” 56” 60”

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Example: A pipe with a nominal pipe size of 4” (100 mm) is available in the thicknesses and diameters below:

Outer diameter in mm

Interior diameter in mm

Thickness in mm

Schedule

114.3

102.3

6.00

40

114.3

97.2

8.55

80

114.3

87.3

13.50

160

Table 8: Various thicknesses of a 4” carbon steel pipe

IMPORTANT: For each material the Schedule changes After construction and assembly, the pipes are submitted to a radiographic check of the weldings and a hydrostatic test. The tests may be conducted on part or all of the network in compliance with the specifications. To take into account the corrosive or erosive effect of the fluids, a supplemental thickness, called a corrosion allowance, is generally defined at 1.5 mm for slightly corrosive services or 3mm for the other services.

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Figure 37: Tube dimensions - carbon steel type

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4.3.3. Choice and principle of changing the class The choice of the pipes, flanges and gaskets is made during the engineering phase. Starting from the wellhead we find a series of pipes destined for high pressure; depending on the equipment that is found downstream, the series will evolve towards much more conventional one.

4.4. EXERCISES

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5. PIPING OPERATIONS The operator has a certain number of responsibilities, especially when concerning interventions on lines or equipment. He is responsible for the observance of the isolation procedures before all work. In addition to his knowledge of the site, he must, during start-up or shutdown, sign a document specifying the positions and the types of blinds which have been placed for works.

Figure 38: Example of blinding

Before and afterwards, he must ABSOLUTELY verify the list of blinds.

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He has the following document at his disposal:

Process Line

Blind in Operator Initials

Blind Out Operator Initials

Feed Inlet (1)

Feed Inlet (2)

Reboiler Outlet

Reboiler Inlet

Vapour Inlet

Product Inlet

Table 9: Document with positions of the blinds

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5.1. PRECAUTIONS BEFORE START-UP Before signing the blind removal list the operator must: Ensure that the whole of the work is finished. Check the inside of the storage capacity to see if everything is clean and free of all waste Check that all the blinds have been removed. Check that the new gaskets have been installed It is also necessary to clean the inside of the pipe to eliminate the debris or other waste which could be found inside, either by blowing or by rinsing. The leak tests help check the pipe sealing by increasing the pressure in the pipe usually to 1.5 times the design pressure (providing the pipe has been calculated for such a pressure).

5.2. PRECAUTIONS TO TAKE BEFORE SHUTDOWN OR INTERVENTIONS Depressurisation Before any intervention, it is imperative to depressurise the pipes; an intervention on a pressurised pipe must in NO CASE be attempted. Drainage Thoroughly verify the drainage at the low points. Inerting Necessary for any intervention on the line (opening of a flange, replacement of a gasket) Notes: Embrittlement problems on a line require specific precautions. In case of welding, verify the residual thickness of the pipe, (see chapter corrosion)

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5.3. 1st DEGREE MAINTENANCE Pipes are usually not submitted to preventive maintenance as are safety valves and other equipment. As we have seen they are nevertheless subjected to corrosion or shocks which sometimes damage a part of the line. In this case the intervention is obligatory and the actions to be carried out are even the more dangerous as the transported fluid is either a gas, or a fluid under pressure or temperature. The type of intervention on a pipe is either a temporary light repair (fibre glass, collars, or insulation) or a heavy reparation, demanding welding or other technical intervention. Maintenance consists of: Monitoring the sealing (check the tightening of the flanges) Outer protection with paint Monitoring of internal corrosion (measurement of the thickness with ultrasound, corrosion coupon)

5.4. EXERCISES

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6. TROUBLESHOOTING 6.1. PIPING PROBLEMS 6.1.1. External corrosion Corrosion is the deterioration of a substance due to a chemical reaction to its environment. The substance does not necessarily have to be a metal. Wood, ceramics, plastic and other materials can also be corroded. If a material becomes corroded its properties will change and it will no longer correspond to its characteristics. Generally speaking, no corrosion occurs in a vacuum. Salt water is more corrosive than soft water Hot water is more corrosive than cold water. Hot air is more corrosive than cold air. (if T° C < 80 °C) Humid air is more corrosive than dry air. Polluted air is more corrosive than clean air Acids are more corrosive than alkaline compounds

Important, this information consists of generalities which must be checked according to the sites! Most of the corrosion which develops on the metals is electrochemical. This corrosion can develop on the inside or outside of a piece of metal equipment. To protect our equipment, various solutions are placed on or in the pipes. The pipes deteriorate mainly because of corrosion and erosion.

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Figure 39: Coupling of insulated pipes

Figure 40: Insulator for flanges Protective coatings can also be used to protect the systems. The outside of the pipe can be painted with special protective paints. Special coatings are usually used on the subterranean systems. Plastics and epoxy are some of the newest coatings used for protection against corrosion.

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6.1.2. Internal corrosion Piping networks and static equipment can be affected by both external and internal corrosion. It is much more difficult to detect the internal corrosion. It can decompose the inner surface causing a corrosion accumulation. To eliminate internal corrosion, or to slow down its progression, special coatings are used. Certain chemicals are also used and injected into the pipes in order to inhibit the action of the corrosion or other fluids. In case of internal corrosion, it is vital to eliminate the source of the corrosion and to determine the extent of the problem, allowing adapted repair. Wear is greatest at the elbows owing to liquid friction from the changes in direction at the low part of their section.

6.1.3. Other causes of deterioration It is dangerous, because of risks of rupture: To use a pipe as support without careful consideration To exert a force on small-diameter pipes To walk on a pipe Furthermore, walking on a pipe constitutes a dangerous act (fall, deterioration of the insulation materials of the heat-proof pipes). Finally, leaks from petroleum products comprise risks. It is prudent to foresee clamp collars of various diameters to rapidly seal a leak. Take into account the corrosion to the support-flanges, thermal insulation and welded tapping. They are actually zones where the corrosion spreads due to the friction or the movements of the pipes.

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6.1.4. Protections There are three main types of protection Thermal protection Personnel protection Protection against shocks The piping receives: A cathodic protection, when the nature of the environment suggests a corrosive action because of an electrolysis effect. A thermal insulation, when it transports hot substances (heat reduction, protection against fire and the burning). An electrical continuity between flanges (put in the ground). A corrosion-protective covering and an outer paint (traditional shades).

6.2. NOTES

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7. GLOSSARY

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8. SUMMARY OF FIGURES Figure 1: Piping network ......................................................................................................6 Figure 2: The definitions of a tube .......................................................................................9 Figure 3: Used abbreviations .............................................................................................11 Figure 4: Welding neck flange ...........................................................................................12 Figure 5: Socket welding flange.........................................................................................12 Figure 6: Threaded flange..................................................................................................13 Figure 7: Flat face..............................................................................................................13 Figure 8: Raised face.........................................................................................................14 Figure 9: Ring joint.............................................................................................................14 Figure 10: Pressure curve according to the series.............................................................21 Figure 11: Ring type joint facing ........................................................................................22 Figure 12: Flat face............................................................................................................22 Figure 13: Raised face.......................................................................................................23 Figure 14: Male and female facing.....................................................................................23 Figure 15: Tongue and groove facing ................................................................................24 Figure 16: Positioning the hydraulic bolt tensioning cylinder on the screw ........................26 Figure 17: Drawing of the screw ........................................................................................26 Figure 18: Positioning the nut ............................................................................................27 Figure 19: Tightening sequence of the bolts ......................................................................28 Figure 20: Tightening sequence for various types .............................................................28 Figure 21: Soft gasket........................................................................................................30 Figure 22: Synthetic rubber gasket ....................................................................................31 Figure 23: Synthetic fibre gasket .......................................................................................31 Figure 24: Spiral wound gasket .........................................................................................32 Figure 25: Ring joint gaskets .............................................................................................33 Figure 26: Metal-elastomer gasket ....................................................................................33 Figure 27: Positioning a metal-elastomer gasket ...............................................................33 Figure 28: Gasket with inner reinforcement and alignment ring.........................................34 Figure 29 : Flush joint ........................................................................................................36 Figure 30: Spectacle blind .................................................................................................36 Figure 31: Assembling a spectacle blind ...........................................................................36 Figure 32: Spectacle blind in open position .......................................................................37 Figure 33: Spectacle blind in closed position .....................................................................37 Figure 34: Blind flanges .....................................................................................................37 Figure 35: Blind flange .......................................................................................................38 Figure 36: PID Fuel gas scrubber ......................................................................................47 Figure 37: Tube dimensions - carbon steel type ................................................................50 Figure 38: Example of blinding ..........................................................................................52 Figure 39: Coupling of insulated pipes...............................................................................57 Figure 40: Insulator for flanges ..........................................................................................57

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9. SUMMARY OF TABLES Table 1: The various classes of flanges (TOTAL and ASME)............................................16 Table 2: The new names for the ANSI flanges ..................................................................18 Table 3: Maximum pressure allowed according to ASME standard B 16, 5.......................19 Table 4: The use of the various classes.............................................................................20 Table 5: Example of a table with tightening torques ..........................................................25 Table 6: The main fittings...................................................................................................29 Table 7 : Type of material according to the fluid ................................................................35 Table 8: Various thicknesses of a 4” carbon steel pipe......................................................49 Table 9: Document with positions of the blinds..................................................................53

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